System Manual Group 13
Contents
1. 1 2 5 Size Although Eagle Manufacturing has many large warehouses including a new 40 000 square foot facility the space for the filling station is limited The size of the scale will probably be the limiting factor of the size of the station 1 3 Marketing Requirements Although we are designing this filling station specifically for Eagle Manufacturing the design could be used in multiple applications in industry Once the design is tested and proven a patent may be pursued and the machine may be put into production In order to be marketable to industry several marketing factors must be taken into account These factors are described below 1 3 1 Procurement Costs The system should be cost effective The objective cost of procuring the filing station would depend on the options size and quality of components 1 3 2 Annual Maintenance With this machine annual maintenance should be relatively small If the machine is in a relatively clean dry environment the only maintenance should be occasional calibration of the scale 1 3 3 Training Time 52 The users should be able to learn the system in 10 minutes or less The touch screen will explicitly state each instruction step by step After each step there will be a prompt confirming each choice and a back cancel button in the case of a mistake 1 3 4 Infrastructure Costs In order for industry to desire implementing such a machine to their facility the setup costs must also b2. 1 includes 2 5 to 2 transition on inlet outlet and 2 check valve on inlet 2 Includes 3 5 to 3 transition on inlet outlet and 3 check valve on inlet cu ft I Ibs Kg Ibs Kg Pu 325 148 SRC Vacuum Receiver SRI Vacuum Receiver Remote Proportioning Valve Flange Mount ccc S WHITLOCK MATERIAL HANDLING Specifications appearances and dimensions are subject to change without notice 78 Model A B c D E F 6 j ee SRO SRCIS RO pe SRC16 Vacuum Receiver SRH01 Vacuum Receiver Mounting Pattern Flange Mount Configuration _ 0 312 clearance holes on 11 00 dia J ah LR TV 10 cutout required UT for mounting i i aa l i n d Jh 12 00 flange outside N gf E diameter E PA Noe F EE EL N ni e 0 312 clearance holes fi Fi on 15 00 dia J Tf i E i i 16 00 flange outside m diameter E i 14 cutout required for mounting SRC30 60 SRH01 SRC16 Specifications appearances and dimensions are subject to change without notice 79 General Notes 0 03 0 1 0 2 0 4 0 8 and 1 6 cu ft models have vacuum outlet mounted on the side of the cover 3 0 and 6 0 cu ft models have the vacuum outlet at the top of the cover ccc S WHITLOCK MATERIAL HANDLING SRI Dimensions in cm 375 16 375 16 1612 2 2 9 32 7 14 mm dia holes 4 places
3. ft models Removable aluminum inlets and outlets on most models SRH 01 stainless steel non removable SRC 02 04 removable aluminum 1 5 2 5 O D SRC 08 16 removable aluminum 1 5 3 5 O D SRC 30 60 removable aluminum 2 0 4 0 O D SRC 30 60 stainless steel welded non removable 4 5 5 O D sch 10 SRC receivers include counter weighted angle discharge throat with throat gasket seal SRH 01 1 5 throat SRC 02 16 4 throat SRC 30 60 6 throat Stainless steel filter screen 10 mesh 0 03 1 6 cu ft models stainless steel pellet deflector 3 0 6 0 cu ft models Vacuum outlet on side cover SRH01 and SRC02 16 models Vacuum outlet on top of cover straight outlet SRC30 60 models Note optional outlets available for SRC 30 60 Sight glass models feature Pyrex sight glass 10 mesh stainless steel screen and square flange SRIO4 includes check valve for single line Y applications OPTIONAL REMOTE PROPORTIONING PACKAGE e Includes proportioning valve 2 aluminum pick up wands 2x10 vinyl flex hoses 4 hose clamps and controller assembly 1 5 2 2 5 OD inlet outlet Hopper floor stand or wall mounting e 115 1 60 230 1 60 or 24 VDC supply voltage e 115 1 60 or 24 VDC control voltage For 1 75 and 2 25 OD uses use aluminum transitions couplers quote separately TT SRC Vacuum Receivers OPTIONAL FEATURES Volume fill sensor 180 F maximum 24 VDC or 115
4. Output 1 199 00 Electrical System to Tie in Blending Station and Electronic Scale Pro face HMI Screen 2 080 00 Allen Bradley MicoLogix 1100 16 PLC Controller 580 29 Allen Bradley 1606 XL 60W Power Supply 282 92 Steel Stand to Mount Hopper Built by EAGLE 250 00 Contingency Costs S 367 79 Total Investment Not to Exceed 18 000 00 Quote 1Q 151559 R2 l 101 IM 0302 an ACS company 04 21 2015 Scott Trimmer EAGLE MANUFACTURING CO INC 2400 CHARLES STREET WELLSBURG WV 26070 Phone 304 737 3171 X129 Fax 304 737 1752 Email strimmer eagle mfg com Dear Mr Trimmer Thank you for requesting the following proposal for AEC Auxiliary Equipment This proposal provides pricing for AEC Vacuum Conveying equipment Application data is incomplete at this time however as a general guideline the Vacuum Pumps are sized to handle approximately 600 Lbs Hour at approximately 50 Equivalent Conveying distance Eagle intends to utilize this system to convey HDPE pellets regrind and sand Proposal is updated 4 10 15 to remove the VT TV upsize the VPS Vacuum Pump and include Proportioning Valve Special Dual Tube Pickup Wands Hoses and option Wear Resistant Packages and enhanced filtering Proposal is updated 4 21 15 to include enhanced filtering on all items and include wear resistant packages on the Vacuum Receiver and Proportioning Valve Pricing together with terms of sale and delivery information is shown on
5. equally spaced MNAE 2 i l 125 23 23 125 1 Model not shown 5 1 7 SRI01 Vacuum Receiver Specifications appearances and dimensions are subject to change without notice SRI02 Vacuum Receiver 80 4 10 7 18 7 18 a d EA ID H a A al Eod F SRI Mounting Flange CL WHITLOCK MATERIAL HANDLING WHITLOCK e MATERIAL HANDLING VACTRAC PROPORTIONING DEVICES VacTrac RPV remote proportioning packages proportion virgin and regrind materials in conjunction with central vacuum receivers AV and SV sequencing valves are used for sequencing vacuum and central vacuum conveying appllications All VTPB blowback pumps use SV style valves STANDARD FEATURES RPV packages feature proportioning valve assembly 2 aluminum pickup wands two 10 vinyl flex hoses four hose clamps an O ring coupler and a controller assembly with quick connect cable assembly specify voltage Line sizes available OPTIONAL FEATURES T5 20 29 Remote Proportioning Valve Hopper mount wall mount or floor stand RPV e Spare controller assembly RPV Consult factory for other line sizes or voltages 25 83 TM DE MMT iTi LULU TIONING RPV REMOTE PROPORTIONING VALVE Available in 1 5 2 0 or 2 5 OD inlet outlet tubes Hopper mount HM stand mount SM or wall mount WM AV SV AIR OPERATED SEQUENCING VALVES Vacuum
6. line size OD Sequence Sequence valve Atmospheric valve in mm T valve plugs 1 5 38 1 SV1 5 SV1 5P AV1 5 2 508 SV2P 1 1018 NG ccc S WHITLOCK MATERIAL HANDLING Specifications appearances and dimensions are subject to change without notice 84 Software Design HMI Screen PLC Program 27 1 Home EAGLE z Ta a Project Name CAUsers senior design Desktop Senior DesigniSeniorDesign2 mgp Screen Description Backlight Color 15 28 SeniorDesign2 mgp 004 2 Drums Project Name CAUsers senior design Desktop Senior Design SeniorDesign2 mgp Screen Description Drums Backlight Color 15 29 SeniorDesign2 mgp 005 4 Single 14 gal Project Name CAUsers senior design Desktop Senior DesigniSeniorDesign2 mgp Screen Description Backlight Color 15 30 SeniorDesign2 mgp 006 10 Single 20 Gal Project Name CAUsers senior design Desktop Senior DesigniSeniorDesign2 mgp Screen Description Backlight Color 15 31 SeniorDesign2 mgp 007 11 Single 30 Gal Project Name CAUsers senior design Desktop Senior DesigniSeniorDesign2 mgp Screen Description Backlight Color 15 32 SeniorDesign2 mgp 008 12 Single 55 Gal Project Name CAUsers senior design Desktop Senior DesigniSeniorDesign2 mgp Screen Description Backlight Color 15 33 SeniorDesign2 mgp 009 13 Single 65 Gal Project Name CAUsers senior design Desktop Senior DesigniSeniorDesig
7. p o Bl Y205 Jy oe E T3 BY2305 AT Stage 4 B 101 Bl Y 007 Bl Y O08 Bl Y207 s E N E HI Bl Y207 Y207 B T4 Bl Y 307 39 AE E T4 El Y307 gt 50 Stage 5 B 101 B yoo Bl Y O10 Bl Y 209 51 OUT gt El 209 Bl T5 Bl Y 309 so YA Main Program Page 5 of 7 40 Page 5 of 7 Total Pages NewProject1 Timer ON Delay T5 El 309 a 53 Stage 6 B 101 B yo Bl Y012 Bl 211 5 i Y or El Y211 55 p o E T6 Bl Y 311 4 56 Stage T El 101 El Y013 Bl YO 14 El Y213 57 ML QUT gt El Y213 E T7 El Y313 s E BEE om ET7 El 1313 59 Stage 8 IB Y 101 B Y015 B Y016 Bl 215 60 OUT gt B Y215 B T8 B 1315 9 YH con Main Program Page 6 of 7 41 Page 6 of 7 Total Pages NewProject1 Main Program Page 7 of 7 Timer ON Delay Y315 62 63 42 Page 7 of 7 Total Pages Test Results Our tests began with calculating the correct mixtures of materials for each drum and weight combination The mixing of the sand and resin had to be measured by mass rather than volume due to the measurements given by the scale The table below shows the total mass of sand and resin required in Kg The results only showed one impossible combination with sand and resin This combination was the 14 gallon drum and 100 Kg Capacity gal capacity m3 Mass kg z Sand kg id Resin kg Ba 0 05299574 17339083 0 052995 7
8. problem 1 1 5 Easy Calibration The Electro mechanical Drum Filling Station must be easy to calibrate The scale is most likely the only piece of the station that will require calibration 1 1 6 Expandability This function will allow the engineers of Eagle Manufacturing to add edit and delete drum sizes and fill amounts easily 1 2 Engineering Requirements There are several engineering requirements that must be implemented in the design of the Electro Mechanical Drum Filling Station These requirements are described below 51 1 2 1 Fill Speed The speed that the drum is filled is important This task is not as easy as one may think Overfilling will require a worker to remove some of the material from the drum by hand The speed of the material flowing into the barrel will be reduced as the barrel approaches the target weight 1 2 2 Fill Weight Accuracy The scale should be accurate to within a pound This will require regular maintenance such as recalibration and testing 1 2 3 Reliability Eagle Manufacturing should be able to expect many years of usage of the electro mechanical drum filling station 1 2 4 Ease of Use The user of the filling station should be able to use the station with very limited training if any at all The user should be able to walk away once the filling has begun The whole process that the user goes through should require less than 1 minute of time not including the actual filling of the drum
9. the attached price page To assist you in evaluating this proposal we are enclosing sales literature and component specifications for your review AEC offers the most technically advanced chilling and mold temperature control systems conveying systems dryers and blenders as well as granulators robotics and automated parts handling equipment available to industry today An array of engineering and installation services are available as well as plant layout and other mechanical or structural drawings Electrical and flow schematics are included with all equipment and systems Field installation supervision mechanical installation and complete turnkey installation services are also available Thank you for your continued interest in our products and services Please feel free to contact us at your convenience to discuss any questions you may have We look forward to being of continued service to you Sincerely Dave Manners Systems Engineer ACS Sales Phone 847 273 7708 Fax 847 273 7804 dmanners acscorpemail com cc Craig Bradford ic Keith Larson ALLEGHENY MACHINERY GRP INC VP of Sales amp Marketing Phone 724 794 3058 Joe Dziedzic Fax 724 794 3081 Application Engineering Manager Email craigo zbzoom net Sq S OQ A O 025 Y YM MATERIAL HEAT amp COOL 2 ERANULATE DOWNSTREAM AUTOMATE SYSTEMS SERVICE HANDLING RECLAIM EXTRUSION CONTRACTING AEC 1100 East Woodfield Road Suite 588 Schaumburg IL 60173 Te
10. 1 HMI Screen Scale Hopper PLC RSLogix Vacuum pump amp hose N UL Se ow qe Appendix 2 Website On Redmine 61 Appendix 4 The general design of the electro mechanical drum fill station remained the same The design still includes a hopper HMI touch screen Allen Bradley PLC scale and a vacuum pump and hose The new components added included a vacuum receiver aluminum double tubing dual tube pick up wand flex hose a remote proportioning valve and blending system The vacuum receiver cots about 62
11. 4 0 075 7082 0 075 7082 0 1135623 0 1135623 0 1135623 0 20819755 0 20819755 0 20819755 0 20819755 0 24605165 0 24605165 0 35961395 26 82660917 102 644453 11 9865 542 34 240956 3 90 53145062 70 343113 27 96 5241 3834 19 87226988 150 7803952 216 2344579 281 6885205 130 5920579 201 5001832 233 2984213 43 Safety Precautions In an industrial setting safety is the number one priority The machine assumes that a drum is in position and the hoppers are clear from obstructions We implemented stop buttons and emergency stop buttons to stop the machine from taking any further action after it has returned to a stationary state Improper use of the machine is very dangerous The machine should only be used to fill the designated drums to the designated weights given in the current simulation Other sizes can be added by experienced technicians to enhance the machine 44 Reflections Throughout the process of designing we ran into a couple problems that hindered our ability to easily design the electro mechanical Drum Fill Station We needed the RSLogix 500 and 5 000 software to complete the process of getting the HMI screen to work with the PLC This software needed to be purchased for us to use it but the cost hindered us 5 000 from purchasing it The cost of everything was the main hindrance in why we could not fully complete the project Not only did the software need to be purchased but all of the hardwa
12. 4 I DS20 Il D310 E Ds20 MO DSTI Bl Y 01 BEE our IB v404 E D320 Il DS311 E D320 E D312 B voi A gt eg our 9 IBI Y404 Il DS20 Il D312 D3520 DS13 Bl v043 HH PP our B 404 Il DS20 Il D313 El DS20 Il DS514 B Y014 BEE our IBI Y404 E DS20 Il D314 E DS20 El D315 Bl 045 A EE EE our 9 IB Y404 Il DS20 m D815 DS20 DS16 Bl Y046 HA A Pr OUT Main Program Page 2 of 7 37 Page 2 of 7 Total Pages NewProject1 p om B Y101 ae Output to Sand Solenoid for dispensing El 001 35 El Y OO2 El TEO B Yogs El Y OO6 El TEO Bl voog Bl YO 10 E T60 BYo13 El Y014 E T60 Output to Resin Solenoid for dispensing BYoo3 36 El YO OA Bl T6 El Y OO El Y OO8 El T6 1 E 011 Bl Y 012 El T6 1 El Y 015 Bl YO 168 E TG 1 Il D316 El Y 110 Bl Y816 HI OUT El Y815 N OUT Main Program Page 3 of 7 38 Page 3 of 7 Total Pages NewProject1 Timer ON Delay E T60 El Y002 Tao 37 YOO6 El Y010 El Y014 El Y004 T61 38 Y008 El Y012 El Y016 Stage 1 IBI Y 101 Y001 Y002 IBI Y201 39 OUT gt IBI Y201 Y201 T1 Bl Y 301 40 4 OUT y El T 1 El 301 41 Stage 2 IB Y 101 Y003 El Y004 Bl Y203 42 t HL OUT El Y203 Y203 IB T2 Bl Y303 43 gt OUT Main Program Page 4 of 7 39 Page 4 of 7 Total Pages NewProject1 Timer ON Delay T2 El 303 v 44 Stage 3 B 101 Byoos Yous Bl Y205 i i
13. D OR IMPLIED INCLUDING BUT NOT LIMITED TO AWARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE NO ORAL WARRANTIES OR GUARANTEES OF ANY KIND HAVE BEEN MADE TO BUYER 6 The Warranties herein shall not be binding upon Seller unless all payments called for by the terms of this contract are and continue to be paid on the dates specified 7 STOP WORK In the event that Seller or an affiliate of Seller s is unable to proceed with the manufacture and shipment of Buyer s order either due to Buyer s request or as a direct or indirect result of any governmental action or regulation Seller shall promptly notify Buyer and a Stop all work on the order as promptly as reasonably possible and store all finished and unfinished items at Buyer s risk b Seller shall invoice Buyer and Buyer shall pay the established costs pursuant to paragraph 2 above C Reinstate Buyer s order at the earliest possible date subject to Buyer s acceptance of prices terms and shipping schedule quoted preliminary to such reinstatement Seller shall allow buyer appropriate credit for parts held in storage by Seller as Buyer s property if such parts can still be used in filling Buyer s Reinstated order d In the event Seller is not permitted to reinstate Buyer s order within 30 days of our notification of stop work we shall scrap Buyer s stored property and credit Buyer with the scrap value 8 FORCE MAJEURE Seller shall not be liable for any delay in performance or nonperf
14. Electro Mechanical Drum Filling Station EAGLE SERE Group 13 Ryan Trimmer Mathew Dunbar Brandon Rau Seth Howdershelt ABSTRACT As college students we are asked to complete a capstone project to put many things we learned throughout college to a real world application As engineering students luckily we get to choose our own capstone project This project should be something that involves many things we have learned and even things that we haven t This project is very important as it puts the students in a real world engineering design process and teaches them that there is a lot more work to being an engineer than just designing and building things Eagle manufacturing has come in contact with us and asked us to design a machine that will automate a process that takes their maintenance workers hours a day This machine will fill drums of specified sizes to specific weights via two fill materials To start this project we collaborated with Eagle s head electrician and various engineers to come up with a design that they could use and fix if it were to incur problems This design involved using materials and components that they are already using in their manufacturing plant We did not achieve everything that we had planned partially because of funding issues and partially due to the fact that there was more to the design and integration than initially thought We did achieve a HMI program a PLC program a complete part
15. RH 01 and SRC 02 models SRI 01 has a 4 inch 101 6mm square mounting flange SRI 02 and 04 have a 7 inch 177 8mm square mounting flange UNIT SPECIFICATIONS Material inlet connection size 1 1 2 40 mm OD Vacuum outlet connection size 1 1 2 40 mm OD Will this receiver be used on a distributive VO No local VO only system Control voltage 24 115 VAC Receiver capacity 0 4 cuft 11 liters Dimensions H x W 22 38 x 12 57 cm x 30 5 cm Shipping weight 33 Ibs 15 kg Includes Upgrades to polyester cloth filter in lieu of standard screen Compressed air blowback with stand alone controller Wear wrap for abrasive materials Includes stainless steel inlet in lieu of standard Check valve removed NOTE Not a warranty item wear is part of the process Quote IQ 151559 R2 AEC 1100 East Woodfield Road Suite 588 Schaumburg IL 60173 Page 5 of 8 ae multi Bote Line Qty 103 1 RPV Proportioning Valves VLV PROP RPV 1 50 1 50 B24 HM APPLICATION TECHNICAL DOCUMENTATION Proportioning Valve AEC s remote proportioning valve is designed to proportion virgin and regrind materials with central vacuum receivers All remote proportioning valves include Proportioning valve assembly Two 2 aluminum pickup wands as standard configuration below may vary Two 2 10 foot lengths of vinyl flex hose as standard configuration below may vary Four 4 hose clamps and o ring coupler Volta
16. RONGAR on 4 15 2015 11 05 48 AM VPR Series VPL Series VPS Series VP SERIES VACUUM PUMPS The new VP Series provides a complete conveying system with controls filter and blower all in one for a compact and versatile unit With 5 different filter types the VP Series can convey pellets regrind and dusty materials over short to medium distances and is available in open or closed loop operation With a compact assembly as a stand alone unit the VP Series sets itself apart from the competition lt can be placed any where on the shop floor and has many configuration options to suit your needs an ACS Group COmpany COMPACT DESIGN VERSATILE FEATURES VPL and VPR models provide up to a 9 station operation either with remote or builtin valves to provide trouble free conveying Unit shown with optional Extended Filter Conveying Distance Conveying Distance Vacuum Inlet Material Inlet Material Inlet HP kW HP kW 100 eq ft 60 hz 100 eq ft 50 hz fail mm Ee pfe 60hz 50hz 260 50H A Ibs hr kg hr Ibs hr kg hr 50Hz 60Hz Q 50Hz Note There are many models and many possible combinations available Conveying rates are estimated based on 100 eq ft additional rates vary by distance and horsepower Weights and dimensions may vary depending on model Please consult your sales representative for additional options Soga 7 3 24 VDC AEC is committed to a continuing program of
17. VAC control voltage not available on 0 03 0 1 cu ft models Stainless steel 20 mesh screen for micro pellet applications Polyester cloth filter in lieu of standard screen deflector Nylon filter in lieu of standard screen deflector 150 mesh e OptiView riser assembly flange mount 150 ambient max temp not available on SRC 30 60 e Machine mount adapter for OptiView or aluminum riser square mounting flange not available on SRC 30 60 Aluminum riser flange mount only not available on SRHO1 or SRI models Silo mount riser with gasketed non vented access door part no A0566986 SRC 30 60 only Aluminum riser with vented access door part no A0566987 SRC 30 60 only High temperature 400 silicone discharge throat gasket not available on 0 03 0 1 cu ft models e White neoprene discharge throat gasket FDA approved 180 F max not available on 0 03 0 1 cu ft models 90 vacuum outlets SRC 30 60 only Adapter to fit TF VF mounting hole 18 dia to 15 dia BC part no A0569579 SRC 30 60 only 70 cone for hard to flow materials in lieu of standard special order only Vibrating pads for 70 cone section special order only e 253mm O D mounting flange no bolt pattern for SRC02 16 in lieu of standard flange part no 822 00616 00 54 SPEGIFIGATIONS cu ft I Ibs Kg Ibs Kg ed 100 45 2 5 3 3 5 4 4 5 64 76 89 101 114 N A
18. aried interpretations of the standards at the local level seller cannot warrant that the machine meets all requirements of the Occupational Safety Health Act Where possible seller will modify the equipment at purchaser s specific request at prices then in effect Buyer is solely responsible for compliance with the Occupational Safety and Health Act and all other state and local environmental and worker health and safety requirements for the installation and use of the equipment CONDITIONS 1 If Buyer does not make full payment when due Buyer shall pay a 296 delinquency charge on any unpaid balance of the Price for each additional 30 day period or any portion thereof that elapses before full payment and reasonable costs of collection including attorney s fees and legal expenses Should Buyer require Seller to delay shipment or completion of the work under this order it is agreed that payment for the Equipment shall not be delayed on this account 2 CANCELLATION Unless otherwise agreed Buyer may cancel all or any part of the order by written notice received by Seller no later than 45 days before the scheduled shipping date On receipt of such cancellation notice all work on the order or part thereof cancelled will be stopped as promptly as is reasonably possible Buyer will then be invoiced for and will pay to Seller as liquidated damages a cancellation charge For completed items the charge will be equal to their established prices For items not co
19. ase consult your sales representative for additional options Weights and dimensions may vary MODEL NAMING MATRIX VPXX X X XXXX Model HN L R S Built In Remote Small Frame Type 1 2 Blower Stage KW Blower Power 1 9 of Stations Electric Air Actuation Type X S P Extended Standard Prefilter Filter Type T Teflon Filter Element Option Example VPS1 1 5 4AST VPS 1 stage 1 5kW 4 station air operated remote valves standard filter with teflon element Ww 4 14 Dead MATERIAL HANDLING 6 SPEGIFIGATIONS VACUUM OUTLET 1 5 amp 20 OPTIONS QUICK CONNECT DISTRIBUTION COMPRESSED AIR INSERT W WHITLOCK MATERIAL HANDLING 1 7 4 14 ac 2 o nc a un a Z gt O a a z a 2 o E z a c gt Z U CONVEYING RATE THOUSAND POUNDS PER HOUR ACS VP SERIES VACUUM PUMP RATE CURVE 60Hz 150 EQUIVALENT FEET ACS VP SERIES VACUUM PUMP RATE CURVE 50Hz 100 150 EQUIVALENT FEET NOTE Rates based on free flowing 1 swa pellets 0 125 diameter with a bulk density of 35 lbs cu ft Any changes can affect the RATES ONLY GUARANTEED rate WITH CORRECT RECEIVER SIZE WHITLOCK MATERIAL HANDLING Mir ll P an an ACS Group COMpany SR VACUUM RECEIVER SR Series Vacuum Receivers from AEC feature a modular stainless steel design offering significant operational advan
20. aterial and a simple means of opening closing the hopper based on whether the user is starting a fill or ending one The last of the requirements comes within the software design The first aspect to the program will be to find a way to implement a scale and a PLC so that the scale output can be read by the PLC and the program continue running based upon that output The program must also interface with the HMI touch screen so that the fill station may be run by a user with simple on screen directions Although there may be many requirements that the design entails this project s expected value for the company is well worth the time and effort making this drum fill station possible Design Achievements All components selected and priced have quotes from manufacturers Design finalized with the selected components HMI menu system created PLC Program created Density of materials calculated Created final design proposal for Eagle Manufacturing President Hardware Design Drum Fill and Weigh Station Project 2015 with WVU Design Team 4 22 15 Blending Station for Drum Fill with Sand and Regrind Plastic to Make Drum Weight AEC VPS1 1 5 1AS Loading System S 6 610 00 AEC SRC Vacuum Hopper S 2 700 00 AEC RPV Proportioning Valve S 2 745 00 AEC Aluminum Double Tube 235 00 AEC Dual Tube Pick Up Wand 745 00 AEC Flex Hose 175 00 AEC Clamps 30 00 AEC Blending System Equipment Sub Total 13 240 00 1 000 Lb Electronic Scale with 4 20mA
21. be Utilized with RPV and Regrind or HDPE Pelletized Material 105 1 Special 1 25 Dual Tube Pickup Wand 745 00 745 00 Includes Reducer from 1 5 to 1 25 To be Utilized with RPV and Sand Material 106 50 A0550737 3 50 175 00 HOSE FLEX CLEAR GROUNDED VINYL 1 5 x 50 Roll Optional Upgrade Hose to Special Urethane to increase protection against wear Consult Factory with exact lengths required Special Order ltem 107 10 W00001917 3 00 30 00 CLAMP HOSE DIX 32 1 56 2 50 Box of 10 Hose Clamps Estimated Shipment 7 to 8 WeeksA R O TOTAL 13 240 00 Terms and Conditions kk kk kk kk kk kk kk kk Submit purchase order to AEC 1100 Woodfield Road Suite 588 Schaumburg IL 60173 Payment due net 30 days commencing with invoice date orders less than 20 000 35 down payment due with purchase order balance due net 30 days orders that exceed 20 000 commencing with invoice date Equipment over 20 000 and over 8 week leadtime 35 down payment orders that exceed 20 000 35 before shipment balance net 30 days International terms 35 Down Payment with order Balance Prior to Shipment unless otherwise determined by ACS credit department Unless otherwise specified in this quotation all shipments are shipped Ex Works best way collect Prices do not include provisions for state or local taxes Prices firm for 30 days NOTE Pictures in this proposal may not reflect final product being quoted
22. desired weight b Must control the suction of the vacuum pumps c Must take output readings from a HMI screen to determine the threshold weight for the drum to be filled to 3 Design a HMI screen interface a Must allow the user to navigate through the selection menus easily b Must have separate options for each drum type which requires the same fill weight c Must properly display the desired weight to be filled to d Must allow the user to start the dispensing process with a single button e Must have an emergency stop button 56 Dispenser actuator Data Flow Diagram HMI Screen Prom selection 57 Operation Flow Chart User Selects Drum on Hl Screen Continue Dispensing Read Current Weight ls Current Weight at 90 of Target ad YES Slow Dispensing Target Achieved 58 Testing The testing for the group s design will be broken up into several smaller tests 1 Testing the RSLogix program 2 Interfacing Scale with PLC output weight onto computer screen 3 Interfacing the hopper dispensing component with the RSLogix program 4 Interface both the scale and the hopper with the RSLogix program Eagle s head Electrician Jeff McKnight will be assisting the group during the tests in order to help work out any problems or answer any questions that may arise during testing If any of the components are unable to be effectively interfaced with the design the group may need to
23. e relatively low This is not a problem with our design as it is relatively modular It could even be portable or put on casters and moved around the facility The only requirements for this station are the power supply and communication line if the company would like to view the status of the station from a remote location 1 4 Mapping of Marketing Requirements to Engineering Requirements The following table describes the relationships between the marketing and engineering requirements sections Marketing Engineering Justification Requirement Requirement s 1 2 1 2 3 4 5 6 The justification of creating a cost effective reliable user friendly and safe filling station is of utmost importance This station will provide Eagle Manufacturing with a machine that replaces the risk of having a worker hurt themselves while saving time simultaneously Annual maintenance costs should be relatively low depending on the quality of the scale used Even with a substandard scale calibration will only take minutes and will only need to be done every few weeks The filling station is designed to be extremely user friendly so training time is miniscule The 53 screen prompts every step to the user and makes them confirm their choice to avoid errors The setup of this station will be very simple There are three main components that must be connected but they are simply plug and play The machine could even be shipped fully assembl
24. ed if need be 1 5 Engineering and Marketing Requirements Tradeoff Chart The following table outlines the tradeoffs between the relationships described in section 3 4 A indicates that as the feature in that column is increased the row is increased simultaneously A signifies a decrease in one feature when the other is modified Design The design of the fill station 1s broken down into several smaller projects which can be worked on separately before integrating them all together One of the projects includes the design of the hopper container in which the material 1s stored and dispensed from which can be created in several different ways A few of the options include having a conveyor belt system in which the hopper delivers the material a gravitational dispensing capability where a door is opened on the bottom of the hopper to allow material to 54 fall down into the drum and a system in which the material is pushed out using a type of large screw in order to prevent congestion of the material at the door which is location on the side of the hopper The software component of this design will be completed using RSLogix 500 and 5000 This software is the software that Eagle Manufacturing uses to run all of the PLCs used throughout their plant The logic of the program to run the hopper is fairly simple The program must start and continue dispensing material until a primary weight threshold is reached th
25. eller in executing one or more financing statements pursuant to the Uniform Commercial Code in form satisfactory to the Seller and Buyer hereby appoints Seller its attorney in fact to execute such financing statements on its behalf so that the statements will be signed by Buyer as debtor said power being one coupled with an interest and not revocable 13 The Buyer shall be in default if he defaults on any payment or any other obligation hereunder or there occurs the death dissolution termination of existence insolvency or business failure or appointment of a receiver of any part of the property of assignment for the benefit of creditors or the commencement of any proceeding under any bankruptcy or insolvency or business failure or appointment of a receiver of any part of the property of assignment for the benefit of creditors or the commencement of any proceeding under any bankruptcy or insolvency laws by or against the Buyer or any guarantor or surety for the Buyer Upon such event of default and at any time thereafter the Seller may declare all obligations hereunder immediately due and payable and shall have all of the rights of a secured party under the Illinois Commercial Code as it is in effect at the time of exercise of such right The Seller may require the Buyer to assemble the Equipment and make it available to the Seller at a place to be designated by the Seller which is reasonably convenient to both parties The Seller may sell the property s
26. ge specific controller assembly with quick connect cable assembly UNIT SPECIFICATIONS Application For a central Vacuum System SRC SRI Series Vacuum Receivers DeviceNet distributive IO system No Local VO only Vacuum outlet size 1 1 2 40 mm OD Vacuum Outlet 1 50 Material inlet size 1 1 2 40 mm OD Material Inlet 1 50 Supply voltage to valve 115VAC Supply Voltage System control voltage 24VDC Number of wands Note A standard RPV for Less all Pick up wands Central convey includes 2 wands amp a std RPV for SLC loaders includes 1 wand Deduct 45 00 for each wand not required Number of 10 foot 3 meters lengths of hose Two 2 10 foot lengths of hose Note A standard RPV for Central convey includes 2 hoses amp a std RPV for SLC loaders includes 1 hose Deduct 20 00 for each hose not required Abrasive Resistant RPV stainless steel body Quote IQ 151559 R2 AEC 1100 East Woodfield Road Suite 588 Schaumburg IL 60173 Page 6 of 8 ae multi quote Line Qty 104 1 PICK MATL AL DBL TUBE 1 5 APPLICATION TECHNICAL DOCUMENTATION Model PW 1 5AD Dual Tube Pick Up Wand 1 1 2 O D 40mm Material Line Connection Double Tube Configuration For Better Air to Material Adjustment Aluminum Construction Quote IQ 151559 R2 AEC 1100 East Woodfield Road Suite 588 Schaumburg IL 60173 Page 7 hi 8 ae multi Quote COMPLIANCE WITH OCCUPATIONAL SAFETY AND HEALTH ACT Because of v
27. he date on which the Equipment is first started and operated where installed 18 If requested by Seller Buyer will give its written approval of the Equipment after installation or delivery but in any event the Equipment shall be deemed approved by Buyer unless Buyer notifies Seller in writing by registered mail at Seller s office within ten days after delivery of the Equipment to Buyer or if installation is specifically called for by this contract then within ten 10 days after start up that the Equipment fails to meet the Requirements of this contract specifying the failings If Buyer notifies Seller that it does not approve of the Equipment Seller shall then have reasonable time to make necessary repairs and adjustments If Equipment then fails to fulfill the Requirements herein specified Seller may at its sole option remove the Equipment upon refunding all moneys paid therefore and thereafter no liability whatever shall exist in favor of either party as against the other and this contract shall thereupon be terminated 19 ACCEPTANCE OF ORDERS Byyer agrees that all orders including any arising from Seller s proposal shall include these terms and conditions only notwithstanding any different or additional items that may be embodied in Buyer s order All orders are subject to acceptance by us in writing 20 Inthe event that changes in the Requirements or the Equipment are made after the acceptance hereof the terms and conditions contained herein
28. house equipment it will greatly reduce the time to only a matter of minutes to fill each drum and will allow for a single individual to fill the drum by a simple touch screen interface 50 1 Requirements Specification 1 1 Functional Requirements This section contains descriptions of each function of the Electro Mechanical Drum Filling Station The functions provide an extremely user friendly cost effective and safe alternative to physically filling the drums by hand All functions will be displayed on a touch based HMI screen 1 1 1 Drum Selection This function should allow a user to select the size and style of drum to be filled There will be a picture of the drum to ensure proper selection Upon selection the software will ask the user to confirm their selection The computer will check the weight of the drum on the scale to ensure that the specified drum is within the tolerance 1 1 2 Amount Type of Material This function will ask the user for the amount and type of material to be put in the specified drum The possible selections will be specific to each type of drum to avoid over filling and confusion 1 1 3 Safety Check The safety check will prompt the user to check surroundings ensure that everyone is clear of moving parts and begin filling once the user has confirmed that the filling station is clear 1 1 4 Emergency Shutoff The emergency shutoff function should immediately stop the filling in case of an emergency or
29. including the limitations of warranty and the grant of a security interest shall apply to such substituted or additional Equipment Quote IQ 151559 R2 AEC 1100 East Woodfield Road Suite 588 Schaumburg IL 60173 Page 8 of 8 ae multi blote W Tri State Supply Quotation TRI STATE SUPPLY COMPANY INC 04 19 2015 CRE Inc FOX COMMERCE PARK TRI STATE SUPPLY COMPANY PAGE NO 67037 EXECUTIVE DR INC ST CLAIRSVILLE OH 43950 FOX COMMERCE PARK 304 233 8311 67037 EXECUTIVE DR Fax 304 233 1965 ST CLAIRSVILLE OH 43950 QUOTE TO SHIP TO bs EAGLE MANUFACTURING EAGLE MANUFACTURING 2400 CHARLES ST 2400 CHARLES ST WELLSBURG WV 26070 WELLSBURG WV 26070 CUSTOMER NUMBER CUSTOMER PO NUMBER JOB NAME RELEASE NUMBER OUTSIDE SALESPERSON 1058 RFQMMORABS o Bill Nethen INSIDE SALESPERSON FREIGHT ALLOWED Ron Gardner OT OUR TRUCK Net 10th PROX 04 15 2015 NO ORDER QTY DESCRIPTION UNIT PRICE EXT PRICE lea A B1763 L16BWA MicroLogix 1100 16 580 290 ea 580 29 Point Controller lea A B1606 XL60DR 1606 XL 60 W Power 282 920 EA 282 92 Supply Thank you for the opportunity to quote Your order would be apprectiated Subtotal Please refer to our TERMS and CONDITIONS as found on our website www tssab com 863 21 0 00 S amp H Charges WASHINGTON FALLSTON WHEELING BUTLER PH 724 225 8311 PH 724 847 9064 PH 304 233 8311 PH 724 586 7000 12 FAX 724 225 8329 FAX 724 847 4541 FAX 304 233 1965 FAX 724 586 7007 Printed By
30. is is a weight below the actual fill weight Once this threshold is reached the program will slow down the rotational speed of the screw to slow the amount of material being forced out of the hopper Finally once the secondary threshold the actual fill weight 1s reached the program will stop the screw rotation completely and shut the door of the hopper to prevent further filling Finally the user interface of the HMI screen will need to be designed The HMI screen will allow the user to pick the desired drum that must be filled for testing and display a screen that has all the information required for the user to know This includes a start stop buttons drum specifications size color ratings and fill weight options for the operator to select from Another key aspect in the design of this project is to keep it as cost efficient as possible Every company tries to reduce the amount of cost in their budgets while trying to increase output in order to obtain higher profits So in turn better designs or equipment or new equipment that can reduce some of these costs are needed e The software components including the PLC RSLogix 500 5000 software scale and HMI screens have prices that range from hundreds of dollars to a couple thousand dollars depending on which type and brand are purchased Finding software and software based devices that are lower in price but still powerful and capable of performing the necessary functions is key e On
31. l 847 273 7700 Fax 847 273 7804 Web http www aecinternet com 1100 East Woodfield Road Suite 588 Schaumburg IL 60173 Price Summary an ACS company EAGLE MANUFACTURING CO INC Quote IQ 151559 R2 Item QTY Equipment Description Price Extended Price 101 1 VPS1 1 5 1AS Loading System 460 3 60 6 610 00 6 610 00 Portable Conveying Blower Filter Assembly 2 HP 1 5 Kw Pump 1 Station Includes Blower 1 Station Controller does not include Vacuum Receiver Includes Upgrade to VP16 acrylic bucket filter with compressed air filter cleaning 102 1 SRC Series Stainless Receiver 2 700 00 2 700 00 HOPPER VACUUM SRCO4 1 5 Connections Time Fill Operation Includes Upgrades to polyester cloth filter in lieu of standard screen Compressed air blowback with stand alone controller Wear wrap for abrasive materials Includes stainless steel inlet in lieu of standard Check valve removed NOTE Not a warranty item wear is part of the process 103 1 RPV Proportioning Valve 2 745 00 2 745 00 VALVE PROPORTIONING RPV 1 50 1 50 B24 HM SPL SS Abrasive Resistant RPV stainless steel body Includes 115 1 60 Supply Voltage 24VDC Control Voltage Timer Control Box 2 Standard Vinyl Hoses 1 5 x 10 with Clamps Quote IQ 151559 R2 AEC 1100 East Woodfield Road Suite 588 Schaumburg IL 60173 Page 2 of 8 ae multi quote 104 1 W00018213 235 00 235 00 PICKUP MATERIAL ALUMINUM DOUBLE TUBE 1 5 To
32. l be to find a way to implement a scale and a PLC so that the scale output can be read by the PLC and the program continue running based upon that output The program must also interface with the HMI touch screen so that the fill station may be run by a user with simple on screen directions Although there may be many requirements that the design entails this project s expected value for the company is well worth the time and effort making this drum fill station possible Background All Eagle drums are made within the plastics department at Eagle s plant Eagles has a vast assortment of drums that vary by size shape and band types in their line of products Each type of drum must be tested for quality control and must meet UN DOT standards before being able to add the UN DOT mark to their drums To meet these standards the drums must be filled with material to certain weights placed in a freezer for 24 hours and then pass two separate tests The first test is a drop test and the second is a stack test Before any of this testing can happen the drums have to be filled This is currently being done by hand by maintenance workers which takes up valuable time and labor which could be used elsewhere While there are several different machines out on the market that could fill drums automatically the cost of buying such equipment does not justify the purchase for Eagle Our design project will greatly reduce cost in making the fill station by using in
33. l payment in full has been made Submitted for AEC by Dave Manners Date April 21 2015 This proposal accepted by Date Authorized Signature Quote IQ 151559 R2 AEC 1100 East Woodfield Road Suite 588 Schaumburg IL 60173 Page 3 of 8 ae multi Pote PROJECT SCOPE This proposal provides pricing for AEC Vacuum Conveying equipment Application data is incomplete at this time however as a general guideline the Vacuum Pumps are sized to handle approximately 600 Lbs Hour at approximately 50 Equivalent Conveying distance Eagle intends to utilize this system to convey HDPE pellets regrind and sand Proposal is updated 4 10 15 to remove the VTTV upsize the VPS Vacuum Pump and include Proportioning Valve Special Dual Tube Pickup Wands Hoses and option Wear Resistant Packages and enhanced filtering Proposal is updated 4 21 15 to include enhanced filtering on all items and include wear resistant packages on the Vacuum Receiver and Proportioning Valve Line Qty 101 1 2 HP 1 Station Portable Conv System APPLICATION TECHNICAL DOCUMENTATION TECHNICAL DOCUMENTATION o Ultra compact design o 4 filter types to convey o Pellets o Pellets 8 regrind o Pellets dusty regrind free flowing powder consult factory o Small cabinet o 1 Pump 1 9 station controls o 2 Patch cords and 2 receptacles per station o Demand amp Sequencing Solenoid field wired o Quick connect distribution block o Compressed ai
34. mpleted the charge will be equal to 140 percent of Seller s full cost as determined by Seller in accordance with Seller s standard accounting practices plus a charge for any packing and storage less a credit for the balance of the material as scrap The full cost includes burden and overhead costs incurred by Seller or by any of Seller s affiliates 3 Purchaser acknowledges and agrees that this AEC purchase order may be fulfilled by ACS Auxiliaries Group Inc or any of its affiliated companies 4 Seller warrants that at delivery and installation the equipment will have the capacity to meet the Requirements set forth on the face hereof provided that Buyer operates the Equipment in accordance with the instructions of Seller Seller also warrants against defects in material or workmanship in the Equipment and agrees to repair or replace f o b point of manufacture any part found by Seller to be defective in material or workmanship within one year from date of shipment The Seller shall not be liable for any special or consequential damage or loss for breach of the above warranties the Seller s liability and the Buyer s exclusive remedy being expressly limited to repair or replacement of defective Equipment or parts thereof under the terms and conditions set out above 5 THE WARRANTIES CONTAINED ABOVE ARE THE ONLY WARRANTIES MADE BY THE SELLER OR ANYONE ELSE WITH RESPECT TO THE EQUIPMENT BEING SOLD HEREUNDER AND ARE IN LIEU OF ANY OTHER WARRANTIES EXPRESSE
35. n2 mgp Screen Description Backlight Color 15 34 SeniorDesign2 mgp 010 14 Single 95 Gal Project Name CAUsers senior design Desktop Senior DesigniSeniorDesign2 mgp Screen Description Backlight Color 15 35 SeniorDesign2 mgp 011 NewProject1 Setting scale target values for example 30 gallon drum and 120 pounds 10 11 12 13 14 15 16 Start Bit HMI X001 Stop bit HMI X002 Not Running Y101 17 El X001 El Y101 MDS1 MDS2 MDS3 ps4 LE D 55 LE D 56 IE DS7 Moss moss IE D510 Mbps MDS12 D813 E D814 IE D815 IE D516 Bl X002 Bl Y 101 OUT Main Program Page 1 of 7 36 Page 1 of 7 Total Pages NewProject1 DS20 holds current scale value from CalEX module 18 18 20 21 23 24 25 26 2f 28 29 30 31 32 33 gt AL our IBI Y404 Il DS20 MO DS E DS20 Il DS2 yoo HA P Pr OUT B 104 I D320 WD Wi D320 El YOO3 cc a el IBI Y404 E DS20 MDS3 DS20 Il DS4 Byona p 5 _ EE our 9 B 404 E DS20 Il DS20 B YOO5 y LL le A AS B 104 I D320 uH D35 I D320 MI DS6 Bl YvOD6G BEE ef our 3 IB Y404 Il DS20 Moss DS20 I DS7 E Yoo HA EE EE OUT Y101 Il DS20 Il DS7 Il DS520 B voos gt lt e a IB 404 I D320 WD I D320 E D S8 B yoga gt A OUT 3 Y404 Il DS20 D39 DS20 D10 Bi yo10 PERE our IB 40
36. olenoid field wired Quick connect distribution block Compressed air filter cleaning for all 3 filter types 1 0 to 2 0 hp 0 85 to 1 5 kW models available Available in Single 4 station or 9 station with remote sequence valves Conveys continuously using an atmospheric relief valve to provide high conveying rates over long distances Suitable for most virgin and regrind applications 50 60 hz 3 phase with 24 VDC control voltage NEMA 12 junction box with fused electrical disconnect OPTIONS Blower sizes Single stage regenerative blowers 1 0 and 2 0 hp sizes available Filter options Compact filter Acrylic filter Teflon filter element Pre filter for dusty material Open or closed loop design Remote proportioning valve Special voltages UPS REM SPEGIFIGATIONS Model HP KW Vacuum Inlet Material Inlet Shipping Weight i i Control Voltage 1 Station Controls 60hz in mm in mm Ib kg VPS1 0 85 1AS 1 0 0 85 1 5 38 1 5 38 290 130 VPStOB51AS 1 0 0 85 38 38 mm 130 VPS1 1 5 1AS 2 0 1 5 1 5 38 1 5 38 300 135 Model HP kW Vacuum Inlet Material Inlet Shipping Weight Control Voltage 1 Station Controls SOhz in mm in mm Ib kg VPS1 0 75 1AS 1 0 0 75 1 5 38 1 5 38 290 130 VPstors1ag 1 0 0 75 _ 38 38 130 VPS1 1 3 1AS 1 7 1 8 1 5 38 1 5 38 300 135 Note There are many models and many possible combinations available Ple
37. or sold The above selection s and pricing are per the enclosed component specifications sheet s and or at Buyer supplied design parameters Alterations in layout details materials and or specified design parameters described in this proposal may result in changes in system performance equipment selection s and or pricing Seller assumes no responsibility for equipment performance in cases where complete application details are not made available by the Buyer If changes beyond the seller s control or the expectation of the buyer or seller require larger or different equipment than originally anticipated the seller will provide the same at a reasonable price Pricing quoted above is less options and or alternates unless otherwise indicated Confirmed shipping date s will be acknowledged after receipt of written formal purchase order s AEC s standard equipment color excluding Automation equipment is warm gray beige Certain components e g motors compressors pipe insulation and tanks may be painted black Terms and Conditions unless otherwise stated amp based upon approved credit The only warranties made by Seller are contained in items 3 and 4 on the last page of this quotation hereof This quotation is subjectto allthe conditions contained on the last page of this quotation hereof Buyer grants AEC or ACS Auxiliaries Group Inc or any of its affiliated companies Seller a security interest in the equipment described herein unti
38. ormance which is due to war fire flood acts of God acts of third parties acts of governmental authority or any agency or commission thereof accident breakdown of equipment strikes differences with employees or similar or dissimilar causes beyond our reasonable control including but not limited to those interfering with production supply or transportation 9 Buyer hereby grants to Seller a purchase money security interest in the Equipment and any and all additions and accessions thereto and proceeds thereof to secure payment of the Price and performance of all Buyer s obligations hereunder Until default under this contract Buyer shall have possession and use of the Equipment subject to the provisions hereof 10 The Buyer will pay when due all taxes on the Equipment or for its use and will keep the Equipment free of any adverse lien or encumbrance and in good order and repair and will not waste or destroy the Equipment or permit it to be attached by legal process or used in violation of any statute or encumbered misused or abused until full payment of the price and any other amounts due hereunder have been received by Seller 11 The Seller may at its option pay taxes discharge encumbrances and pay for insurance repairs and maintenance on the Equipment and any sums so paid by the Seller or for which it shall become obligated shall be repaid by the buyer to the Seller upon demand 12 JAtthe request of the Seller the buyer will join with the S
39. perate a dispenser and check the current weight dispensed to fill containers to the target weight This design will make the task of filling each drum before testing much more efficient and with little effort The program will be preloaded with different specifications and will be able to execute the specific recipe and weight without further input from the user Eagle Manufacturing has requested that the system be designed with similar equipment that is currently in use in the company which includes Programmable Logic Controllers and Human Machine Interface touch screens to keep standards The programs will be modifiable for future expansion or adjustments Introduction There are various requirements in which the drum filling station must achieve One objective is to fill the drums to a specified weight for testing purposes The station must gather data from the scale which will determine whether the PLC program continues or stops the fill cycle based on the current weight of the drum The weights will be implemented into the PLC program beforehand so that there is no need for the user to input a weight Another difficulty comes with the design of the hopper The design will require several key components in order to keep an even flow of the material and a simple means of opening closing the hopper based on whether the user is starting a fill or ending one The last of the requirements comes within the software design The first aspect to the program wil
40. product improvement Specifications appearances and dimensions are subject to change without notice 2013 AEC Bulletin WH2 160 Printed in USA AEC Schaumburg AEC New Berlin AEC Suzhou AEC Warsaw Corporate Manufacuring Facility 109 Xingpu Road SIP ul Dziakowa 115 Headquarters 2900 S 160th Street Suzhou China 215126 02 234 Warszawa Global 1100 E Woodfield Rd 588 New Berlin WI 53151 Tel 86 512 8717 1919 Tel 48 22 390 9720 Headquarters Schaumburg IL 60173 Tel 1 262 641 8600 Fax 86 512 8717 1916 Fax 48 22 390 9724 Tel 1 847 273 7700 Fax 1 262 641 8653 Fax 1 847 273 7804 14 WHITLOCK MATERIAL HANDLING The new VPS Series provides a complete conveying system with controls filter and blower all in one for a compact and versatile unit With 4 different filter types the VPS series can convey pellets regrind and dusty materials over short to medium distances and is available in open or closed loop operation With a compact assembly as a stand alone unit the VPS Series sets itself apart from the competition can be placed any where on the shop floor and has many configuration options to suit your needs STANDARD FEATURES Ultra compact design 4 filter types to convey Pellets Pellets amp regrind Pellets dusty regrind amp free flowing powder consult factory Small Cabinet Design 1 Pump 1 9 station controls 2 Patch cords and 2 receptacles per station Demand amp Sequencing S
41. r filter cleaning available on upgraded filters not on standard filter o 1 0 to 2 0 hp 0 85 to 1 5 kW models available o Available in Single 4 station or 9 station with remote sequence valves o Conveys continuously using an atmospheric relief valve to provide high conveying rates over long distances o Suitable for most virgin and regrind applications o 50 60 hz 3 phase with 24 VDC control voltage o NEMA 12 junction box with fused electrical disconnect UNIT SPECIFICATIONS Model VPS L R S Frame S 1 2 Blower Stage Single stage KW Blower Power 1 5 kw 2 0 hp 1 9 of Stations 1 Actuation Type Electric Air Air operated atmospheric relief valve Filter Type X S P Extended Standard Prefilter Upgraded Filter to VP16 Quote IQ 151559 R2 AEC 1100 East Woodfield Road Suite 588 Schaumburg IL 60173 Page 4 of 8 ae multi alote Line Qty 102 1 SRH and SRC Series Stainless Receivers HPR VAC SRCO4 APPLICATION TECHNICAL DOCUMENTATION SRH and SRC Receivers AEC s SRH and SRC receivers are used for conveying pelletized and regrind material in centralized vacuum conveying system The SRH and SRC receivers come standard with Brushed stainless steel construction Material Demand Sensor 10 mesh stainless steel pellet deflector screen Removable inlets and outlets except on SRH 01 model nternal check valve on material inlet for 1 5 2 2 5 and 3 inch inlets except on the S
42. re as well All of the components needed to be bought for us to be able to build the actual physical drum filling station We could not get this accomplished because the total amount for everything totaled 18 000 The president of the company loved our design but the company could not allocate almost 20 000 in the time frame of our project He agreed to purchase the equipment in the next fiscal year when the budget could allow for such a high expense The only way to have possibly avoided this situation is by designing a simpler station for less cost The down side to this is the amount of automation in the design would be greatly decreased This would in turn increase the amount of manual labor required to perform the same amount of work that the fully automated system achieved 45 Appendix 1 User Manual Check machine to ensure it is in proper working conditions Place empty drum on scale Turn machine on Tare zero scale Select drum volume Select drum weight Check to see that the hopper to drum path is clear Confirm that correct Drum volume and weight are selected Se 2 A A A Press start to begin dispensing material 10 Wait until dispensing is complete 11 Shut down machine 12 Remove drum Press STOP to stop filling at anytime and shut machine down 46 Appendix 2 A Maintenance Manual The machine needs to be free of obstructions and the cylinders need to be properly lubricated to ensure smooth actuation The CalEx mod
43. reevaluate part of the design and come up with a better solution Project Plan Work Breakdown Hardware Design e Ryan Trimmer e Seth Howdershelt e Brandon Rau e Matt Dunbar Software Design e Ryan Trimmer e Brandon Rau e Matt Dunbar Brainstorming for possible designs of fill station 59 uhweae aa Contingency Plans e Possible new components e Help from Eagle s electricians and maintenance workers 60 ee480Fall2014gp13 Electro Mechanical Drum Filling Station mis was 2 41 25H 201412 2051 NS ES GEA SIETE GACETA ee480Fall2014gp13 Electro Mechanical Drum Filling ee480Fall2014gp13 Electro Mechanical Drum Individual Research Paper Final Draft Resolved 100 Proposal for Eagle Manufacturing Resolved 100 Presentation Resolved 100 Peer Report Resolved 100 Extended Problem Report and Requirements Resolved 100 Elevator Pitch ee Resolved 100 Project Technical Merit AAA Resolved 100 Individual Research Paper Draft AAA Resolved 100 Design Proposal f Resolved 100 References Joe Eddie President of Eagle Manufacturing Jeff McKnight Eagle Manufacturing Head Electrician Don Mitchell Eagle Manufacturing Head Design Engineer IEEE Std 100 1996 IEEE Standard Dictionary of Electrical and Electronics Terms IEEE Std 610 12 1990 IEEE Standard Glossary of Software Engineering Terminology Appendix 1 Procurement List
44. s list with prices and a finalized design proposal to submit to Eagle I feel that although we did not complete our project we learned many important lessons We learned that it takes time to allocate money for building things that it is more involved than just combining the parts needed together and that Electrical Engineering is a very broad topic TABLE OF CONTENTS Introduction Design Achievements Hardware Design Price Analysis AEC Vacuum Pump Brochure AEC Vacuum Pump Spec Sheet AEC Vacuum Reciever Brochure AEC Vacuum Reciever Spec Sheet AEC Proportioning Valve Spec Sheet Software Design HMI Screen PLC Program Test Results Safety Precautions Reflections APPENDIX I USER MANUAL APPENDIX 2 MAINTENANCE MANUAL APPENDIX 3 Original Design Proposal APPENDIX 4 Summary of Changes Y U N N 15 19 21 25 27 28 36 43 44 45 46 47 48 62 Introduction There are various requirements in which the drum filling station must achieve One objective is to fill the drums to a specified weight for testing purposes The station must gather data from the scale which will determine whether the PLC program continues or stops the fill cycle based on the current weight of the drum The weights will be implemented into the PLC program beforehand so that there is no need for the user to input a weight Another difficulty comes with the design of the hopper The design will require several key components in order to keep an even flow of the m
45. tages The modular design allows these units to be economically reconfigured to accommodate future production requirements Units are available in different configurations and sized for material throughput ranging from just a few pounds to thousands of pounds per hour Pyrex sight glass models allow for easy visual monitoring of material flow and are equipped with an adjustable proximity sensor to ensure minimal material inventory at each machine MACHINE MOUNT MODELS INCLUDE Brushed stainless steel construction Pyrex sight glass for easy monitoring of material load discharge cycle Adjustable proximity sensor specify 24 VDC or 115 VAC Modular design allows quick economical reconfiguration to accommodate future requirements Quick release design no tools needed to remove hopper cover or sight glass Flat stainless steel filter provides filtration of conveying air Interchangeable material inlet outlet connectors not available on 0 03 0 1 cu ft models Discharge throat flapper for even material flow Available in four hopper sizes 0 03 0 1 0 2 and 0 4 cubic foot capacities Global AEC Schaumburg AEC New Berlin Headquarters Administrative Maufacturing Facility Headquarters 2900 S 160th Street 1100 E Woodfield Rd 588 New Berlin WI 53151 Schaumburg IL 60173 Tel 1 262 641 8600 Tel 1 847 273 7700 Fax 1 262 641 8653 Fax 1 847 273 7804 Volume Fill Switch Remote Proportioning Val
46. the other end of the spectrum the mechanical parts of the design can range even more Several factors can be interchanged in order to build the hopper HMI stand and scale stand The material to be used to build the hopper can be altered depending on how strong it needs to be must be able to hold a certain amount of material to be dispensed Also the physical size of the hopper and stands can lead to varying cost due to more less material used in order to build each 99 e With the implementation of this design the company has the possibility of saving money in other parts of the company This comes from the maintenance workers having more free time to finish projects throughout the plant which maintains the equipment that is used for production of all Eagle products Below is a breakdown of what each project requires It lists the requirements that the group has found would help the fill station function smoothly and accurately based upon the needs of Eagle Manufacturing 1 Design a hopper that dispenses material into the drums a Must prevent material blockage b Must allow for even material flow until proper drum weight is achieved 2 Design a software program using RSLogix 500 and 5000 for Allen Bradley PLCs that will be integrated with the hopper HMI screen and the scale under the drum a Must take output readings from the scale in order to open or close the hopper door depending on how close the measured weight is to the
47. ubject to the security interest created hereby at public or private sale following repossession at which sale Seller may be a purchaser In the event of such sale the Seller shall be entitled to reasonable attorneys fees and legal expenses 14 No waiver by the Seller of any default shall operate as a waiver of any other default or of the same default on a future occasion 15 All rights and obligations of each party hereunder shall inure to the benefit of and be binding upon the successors and assigns of the party 16 Buyer is to prepare the premises and provide proper size openings to receive the Equipment and except when stated specifically to the contrary Buyer is also to furnish and install where required and in accordance with local codes the following lighting water sewer and drain connections steam supply and exhaust connections cutting and patching foundations electric wiring all permits certificates of inspection and fees thereof Buyer is to provide sufficient space at the location where the equipment is installed so that Seller s agents may service such equipment if Seller elects to do so 17 When installation of the Equipment is specifically called for as a part of this contract the date of start up of Equipment shall be considered date of shipment for warranty purposes Such installation work shall be performed only during the usual working hours except when stated specifically to the contrary Start up as used herein means t
48. ule is replaceable with similar models as well as the cylinders Enhancements to the PLC program can be made to incorporate newer drums of varying sizes and weight requirements The program 47 Appendix 3 Eagle Manufacturing Design Proposal Group 13 Electro mechanical Drum Fill Station EAGLE MA Ryan Trimmer Matt Dunbar Brandon Rau Seth Howdershelt 12 3 2014 48 Contents Executive Summary Problem State oes RE Ri ESE GN GR Ri RR ED bee GE AG EK ERGER ERG P Ee EG EG 8 luisse ELIT mmm Error Bookmark not defined ao Mis PP ee mo LO EE E e 8 1 Requirements Specification GE EO 9 SR EG ie rie ed REI Socios 9 EGTE FINN EQUINOS OE EE ER ET ON EO EE UEM nd 9 1 3 Marketing Pee OA EENS oe TO OD mE 10 1 4 Mapping of Marketing Requirements to Engineering Requirements sees ee 11 1 5 Engineering and Marketing Requirements Tradeoff Chart ss ss see ee EE ee 12 E AR EO RR N EE EE EE Q 12 BEd as d EIE Et OE Or 15 AU AA AE N EE N OE EE EE ER n 16 oio 17 AULAS ME oo T PP o EE HE 17 Mii S O o PEE T 19 ae Aa Eee ea E AA o o NE EE EE 19 Appendix 2 Website EE oe o 19 E o eee a ee MM MM Error Bookmark not defined 49 Executive Summary Problem Statement Our project is to design an automated industrial machine to accurately dispense materials according to weight for Eagle Manufacturing Company The system will implement a touch screen to o
49. ve OptiView Riser Aluminum Riser AEC is committed to a continuing program of product improvement Specifications appearances and dimensions are subject to change without notice AEC Suzhou 109 Xingpu Road SIP Suzhou China 215126 Tel 86 512 8717 1919 Fax 86 512 8717 1916 2013 AEC AEC Warsaw ul Dziakowa 115 02 234 Warszawa Tel 48 22 390 9720 Fax 48 22 390 9724 Bulletin WH2 135 6 Printed in USA AEC India Gat No 191 1 Sandbhor Complex Mhalunge Chakan Tal Khed Dist Pune 410501 India Tel 91 21 35329112 Fax 91 20 40147296 ccc S WHITLOCK MATERIAL HANDLING SR Series vacuum receivers from AEC feature a modular stainless steel design offering significant operational advantages The modular design allows these units to be economically reconfigured to accommodate future production requirements Pyrex sight glass on SRI models allow for easy visual monitoring of material flow SRH SRC vacuum receivers are used at each loading point in a central vacuum conveying system 0 03 0 1 and 0 2 cu ft receivers are not to be used on single line Y systems and SRC04 receivers are not recommended They should be used beside the machine or with dedicated lines STANDARD FEATURES Brushed stainless steel construction Material demand level sensor Internal check valve on material inlet for 1 5 2 0 2 5 and 3 0 not available on 0 03 0 1 or 0 2 cu
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